Apparatus and method for manufacture of braided preforms

ABSTRACT

A braiding apparatus may comprise a braiding machine, a lower guide mechanism, and an upper guide mechanism. The lower guide mechanism may comprise a multiple-axis robot or a multiple axis-mechanism. The upper guide mechanism may comprise a multiple-axis robot or a multiple axis-mechanism.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and the benefit of, U.S.Provisional Patent Application No. 61/970,643 filed Mar. 26, 2014, andU.S. Provisional Patent Application No. 61/970,671 filed Mar. 26, 2014,and U.S. Provisional Patent Application No. 61/970,677 filed Mar. 26,2014, and U.S. Provisional Patent Application No. 61/970,668 filed Mar.26, 2014, and U.S. Provisional Patent Application No. 61/970,623 filedMar. 26, 2014, and U.S. Provisional Patent Application No. 61/970,952filed Mar. 27, 2014, all of which were filed with the United StatesPatent and Trademark Office, and each of which is hereby incorporatedherein by reference.

TECHNICAL FIELD

The present subject matter relates generally to a braiding apparatus.More specifically, the present subject matter relates to an apparatusand method for manufacturing braided articles. In some embodiments thebraided articles may be preforms.

SUMMARY AND BACKGROUND

The manufacture of braided articles is of substantial interest.Development of new methods and apparatus to conduct the braiding ofarticle including, preforms, remains of interest.

Provided is a braiding apparatus that may comprise a braiding machine, alower guide mechanism, and an upper guide mechanism. The lower guidemechanism may comprise a multiple-axis robot or a multipleaxis-mechanism. The upper guide mechanism may comprise a multiple-axisrobot or a multiple axis-mechanism.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an elevation view of a braiding apparatus.

FIG. 2 is elevation view of a braiding apparatus braiding a startassembly.

FIG. 3 is an elevation view of a braiding apparatus cutting an overbraidon an overbraid form assembly.

FIG. 4 is a view of an overbraid form assembly.

FIG. 5 is a view of a start assembly.

FIG. 6 is an elevation view of a braiding apparatus operating on aninterconnected overbraid form assembly.

FIG. 7 shows multiple views of the various orientations of aninterconnected overbraid form assembly as it moves though a braidingoperation.

Also attached is an Appendix with drawings showing related subjectmatter.

DETAILED DESCRIPTION

With reference to FIGS. 1-N, an apparatus usable in a method tomanufacture braided articles may be referred to herein as a braidingapparatus 100. A braiding apparatus 100 may comprise a braiding machine120, a lower guide mechanism 140, and an upper guide mechanism 160. Thelower guide mechanism 140 may comprise either a multiple-axis robot 142or another multiple axis mechanism. The upper guide mechanism 160 maycomprise either a multiple-axis robot 162 or another multiple axismechanism. The lower guide mechanism 140 and the upper guide mechanism160 may have coordinated control by a controller 104. In certainembodiments, and without limitation, the braiding machine 120 may be amaypole braider.

The braiding apparatus 100 may further comprise a cutting mechanism 172.The cutting mechanism 172 may be affixed to the upper guide mechanism160 or may be part of a separate mechanism 170. Mechanism 170 may be amultiple-axis robot 174 or another multiple axis mechanism.

The braiding apparatus 100 may be adapted for operational engagementwith an overbraid form assembly 180. An overbraid form assembly 180 maycomprise an overbraid form 182 having a leading form edge 181, a leadguide tool 184 affixed to the leading form edge 181, and a trailingguide tool 186. The overbraid form 182 comprises an overbraid formsurface 182 a which is adapted for forming a braid 118 thereon.Operational engagement of the braiding apparatus 100 with the overbraidform assembly 180 may comprise forming of a braid 118 over the overbraidform 182 by the braiding machine 100 and either 1) engagement of thetrailing guide tool 186 by the lower guide mechanism 140, or 2)engagement of the lead guide tool 184 by the upper guide mechanism 160.

The lead guide tool 184 may comprise a lead grasp feature 185 adaptedfor being grasped by a grasping component 164 of the upper guidemechanism 160. By grasping the lead grasp feature 185, the upper guidemechanism 160 may guide the lead guide tool 184 through a braidformation region 124. The braid formation region 124 is the general areaof the braiding machine 120 where the braided structure 110 begins toform. As the braided structure 110 is laid down on the overbraid form182 the upper guide mechanism 160 is engaged to the lead guide tool 184by lead grasp feature 185 through the braid 118. That is, the braid 118is trapped between the grasping component 164 of the upper guidemechanism 160 and the lead guide tool 184.

The lead guide tool 184 may comprise a lead interlocking feature 188. Alead interlocking feature 188 may be adapted for selectable engagementwith a counterpart feature such as the trailing interlocking feature 189or the start interlocking tool 136 described herebelow. A leadinterlocking feature 188 may be male or female or of other form chosenwith good engineering judgment. A lead guide tool 184 may comprise acutting facilitation feature 183. A cutting facilitation feature 183 mayfacilitate the cutting of the braid 118 and may be, without limitation acutting groove.

The trailing guide tool 186 may comprise a trailing grasp feature 187adapted for being grasped by a grasping component 144 of the lower guidemechanism 140. The trailing guide tool 186 may comprise a trailinginterlocking feature 189. A trailing interlocking feature 189 may beadapted for selectable engagement with a counterpart feature such as alead interlocking feature 188. A trailing interlocking feature 189 maybe male or female or of other form chosen with good engineeringjudgment. A trailing guide tool 186 may comprise a cutting facilitationfeature 183. A cutting facilitation feature 183 may facilitate thecutting of the braid 118 and may be, without limitation a cuttinggroove.

The braiding apparatus 100 may be adapted for operational engagementwith a start assembly 130. A start assembly 130 may comprise anelongated mandrel 132, a start guide tool 134 having a leading startedge 131, and a start interlocking tool 136.

The elongated mandrel 132 comprises an elongated mandrel surface 132 awhich is adapted for forming a braid 118 thereon. In some embodimentsthe elongated mandrel 132 is substantially cylindrical. Operationalengagement of the braiding apparatus 100 with the start assembly 130 maycomprise forming of a braid 118 over the elongated mandrel 132 by thebraiding machine 100 and either 1) engagement of the start interlockingtool 136 by the lower guide mechanism 140, or 2) engagement of the startguide tool 134 by the upper guide mechanism 160.

The start guide tool 134 may comprise a start grasp feature 135 adaptedfor being grasped by a grasping component 164 of the upper guidemechanism 160. By grasping the start grasp feature 135, the upper guidemechanism 160 may guide the start assembly 130 through the braidformation region 124. As the braided structure 110 is laid down on theelongated mandrel 132 the upper guide mechanism 160 is engaged to thestart guide tool 134 by start grasp feature 135 through the braid 118.That is, the braid 118 is trapped between the grasping component 164 ofthe upper guide mechanism 160 and the start guide tool 134. The startguide tool 134 may comprise a cutting facilitation feature 133. Acutting facilitation feature 133 may facilitate the cutting of the braid118 and may be, without limitation a cutting groove. The start guidetool 134 may optionally comprise conventional features for ting orgripping fibers 112, axial bias or otherwise, at the beginning of thebraiding operation.

The start interlocking tool 136 may be graspable by the graspingcomponent 144 of the lower guide mechanism 140. By grasping the startinterlocking tool 136, the lower guide mechanism 140 may guide the startassembly 130 into or through the braid formation region 124. The startinterlocking tool 136 may be adapted for selectable engagement with acounterpart feature such as a lead interlocking feature 188. A startinterlocking tool 136 may be male or female or of other form chosen withgood engineering judgment.

The leading form edge 181 may be the first portion of the overbraid form182 to enter the shed 122 during a braiding operation.

Without limitation, one method for using the braiding apparatus 100 tomanufacture braided articles is as follows.

Lower guide mechanism 140 engages start assembly 130 by grasping thestart interlocking tool 136 with the grasping component 144 and guidesthe start assembly 130 so that the leading edge 131 of the start guidetool 134 is located at a predetermined position in the braid formationregion 124. Fibers 112 are pulled off of bias carriers 114 and/or axialspools 116 and brought to the axis 126 of the braiding machine 120 andup along the start assembly 130. Braiding machine 120 is operated atsome operating speed to generate braid 118 over start guide tool 134 andstart assembly 130 is moved along axis 126 by the lower guide mechanism140 at some predetermined ratio with respect to the operating speed ofbraiding machine 120. Once the braid 118 has formed over the start guidetool 134, the upper guide mechanism 160 may engage the start graspfeature 135, trapping the braid 118 between the grasping component 164of the upper guide mechanism 160 and the start guide tool 134, to guidethe start assembly 130. The lower guide mechanism 140 disengages fromthe start assembly 130. The lower guide mechanism 140 picks up anoverbraid form assembly 180 by engaging with its trailing guide tool 186and engages the lead guide tool 184 of the overbraid form assembly 180with the start interlocking tool 136 on the start assembly 130.Operation of the braiding machine 120 to continue braiding resumes untillead guide tool 184 of overbraid form assembly 180 is in position to beengaged by the upper guide mechanism 160. At this point a repetitiveoperational loop may be initiated. The upper guide mechanism 160 engagesthe lead guide tool 184 of the overbraid form assembly 180 to guide theoverbraid form assembly 180. The cutting mechanism 172 is activated totrim the braid 118 at some desired location above the region at whichthe upper guide mechanism 160 engages the lead guide tool 184. Operationof the braiding machine 120 to continue braiding resumes with the upperguide mechanism 160 and the lower guide mechanism 140 coordinatingmotion through controller 104 so that the axial fibers follow desiredpredetermined paths along the overbraid form assembly 180. When theoverbraid form 182 and a desired portion of the trailing guide tool 186have been braided, braiding stops. The lower guide mechanism 140disengages from the trailing guide tool 186. At this point braiding maystop entirely or if further braiding is desired, continued. Ifcontinuation is desired, the lower guide mechanism 140 picks up a newoverbraid form assembly 180 and engages the lead guide tool 184 of thisnew overbraid form assembly 180 with the trailing guide tool 186 of theold overbraid form assembly 180. Operation of the braiding machine 120to continue braiding resumes until the lead guide tool 184 of the newoverbraid form assembly 180 in in position to be engaged by the upperguide mechanism 160. At this point the repetitive operational loopterminates and operation continues by repeating the steps beginning atthe point of initiation of the repetitive operational loop.

It should be understood that the braided articles to be formed maycomprise any of a variety of desired shapes. In some non-limitingembodiments, the braided articles to be formed may be preforms for usein braided shoes or components of braided shoes, braided preforms foraircraft seat frames, braided preforms for vehicle fuselage frames andfamilies of braided structures of similar geometry but varyingdimensions.

For families of braided structures of similar geometry but varyingoverall or other dimensions, the lead guide tool 184 and the trailingguide tool 186 of the overbraid form assemblies 180 may have varyingextents such that the grasp features, lead grasp feature 185 andtrailing grasp feature 187, are located at a fixed position relative toa common point within the family of braided structures, thereby enablingthe upper guide mechanism 160 and the lower guide mechanism 140 to gripthe lead guide tool 184 and the trailing guide tool 186 at the samefixed position in the braiding space as each overbraid form assembly 180is braided. This eliminates the need for a hunting mechanism to locatethe grasp features.

For braided structures comprised of more than one overbraid layer, theabove-described method and apparatus may be employed to overbraid afirst layer on the overbraid form assembly 180, and subsequent overbraidlayers may be laid over the first layer by feeding the same overbraidform assembly 180, with the first layer thereon, back through thebraiding apparatus 100 and using the apparatus and method as describedto overbraid a second layer on the braided overbraid form assembly 180.In this manner two or more layers of braid may be layered as required.

In some embodiments, multiple apparatus may be used for layers ofvarying fiber content, fiber density, etc.

To facilitate tracking an quality control of preforms some of theoverbraid forms, such as overbraid form assembly 180, may employ anidentification means 192 such as, without limitation, non-contact,non-line-of-sight means like an embedded RFID tag. By using suchidentification means ID and other designation data can be sensed throughany braid layers thereon. Such identification means 192 may bedetectable by detectors 194 in other components in the apparatus.

The overbraid forms, such as overbraid form assembly 180, may beconstant geometry forms selected as required for the production sequenceor, may be comprised of customized or customizable geometric features tofacilitate production of preforms within the range of parts comprisingthe family of parts to be produced.

The overbraid forms, such as overbraid form assembly 180, may beproduced on demand by 3D printing, building up customized geometricfeatures on a standards form by 3D printing, machining customized 3Dforms on demand from a standard master with overall dimensions greaterthan or equal to the maximum dimensions encompassed by the family ofparts, or may be comprised of flexible forms with internal mechanical,pneumatic, or other internal adjustment means to change the outergeometric form of the overbraid form, or the dimensions of a standardmaster form may be altered by selective dipping of the form into ahardenable or semi-hardenable medium chosen with good engineeringjudgment.

The braided structure 110 produced on said apparatus 100 and by saidmethod may be comprised of conventional triaxial braided structures withdry fibers wherein the axial fibers 112 laid into the regular, or plain,braid lock the overall geometry of the braided structure 110 once theoverbraid is fully formed over the entire overbraid form 182.

Alternatively, hot melt fibers may be co-wound with the axial fibers 112with heat then applied to the fully-formed braid 118 continuously orperiodically in the region below the lead grasp feature 185 through tothe trailing grasp feature 187 or portions of said region therebyfurther assisting the retention of the fully-formed overbraid braidedstructure 110.

Alternatively, elastic axial fibers may be substituted for some or allgenerally inelastic fibers to facilitate making preforms of a braidedstructure 110 that can be stretched to remove them from the overbraidform 182 and then return to the original overbraid shape or, onceremove, to permit the braided structure 110 to be stretched over otherforms to facilitate subsequent processing.

It should be noted that the engagement of the above noted interlockingcomponents, start interlocking tool 136, lead interlocking feature 188,and trailing interlocking feature 189 may be rotatable engagementwhereby the engaged components are free to rotate with respect to oneanother about multiple dimensions simultaneously. Such engagement may bechosen with good engineering judgment. Such engagement may includevarious kinds of ball joints.

While the subject matter has been described with reference to certainembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the scope of the subject matter. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the subject matter without departing from its scope.Therefore, it is intended that the subject matter not be limited to theparticular embodiment disclosed, but that the subject matter willinclude all embodiments falling within the scope of the appended claims.

What is claimed is:
 1. A braiding apparatus comprising, a braidingmachine a lower guide mechanism comprising either a multiple-axis robot;or a multiple axis-mechanism; and an upper guide mechanism comprisingeither a multiple-axis robot; or a multiple axis-mechanism.
 2. Thebraiding apparatus of claim 1, wherein the braiding apparatus is adaptedfor operational engagement with an overbraid form assembly, saidoverbraid form assembly comprising an overbraid form having a leadingform edge, a lead guide tool affixed to the leading edge, and a trailingguide tool; and said operational engagement with the overbraid formassembly comprising the forming of a braid over the overbraid form bythe braiding machine, and either engagement of the trailing guide toolby the lower guide mechanism, or engagement of the lead guide tool bythe upper guide mechanism.
 3. The braiding apparatus of claim 2, whereinthe braiding apparatus is adapted for operational engagement with astart assembly, said start assembly comprising an elongated mandrel; astart guide tool having a leading start edge; and a start interlockingtool; and said operational engagement with the start assembly comprisingthe forming of a braid over the elongated mandrel by the braidingmachine, and either engagement of the start interlocking tool by thelower guide mechanism, or engagement of the start guide tool by theupper guide mechanism.
 4. The braiding apparatus of claim 3, whereinsaid braiding machine is a maypole braider.
 5. The braiding apparatus ofclaim 4, wherein said lead guide tool comprises a lead grasp featureadapted for being grasped by the upper guide mechanism; and a leadinterlocking feature.
 6. The braiding apparatus of claim 5, wherein saidtrailing guide tool comprises a graspable feature adapted for beinggrasped by the lower guide mechanism; and a trailing interlockingfeature.
 7. The braiding apparatus of claim 6, wherein said lead guidetool comprises a cutting facilitation feature.
 8. The braiding apparatusof claim 7, wherein said trailing guide tool comprises a cuttingfacilitation feature.